柔性三维拉弯成形工艺稳健设计
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摘要
分析了型材柔性三维拉弯成形工艺的可控因素和不可控因素,提出了该工艺稳健分析优化设计方法。通过有限元模拟,对可控因素和不可控因素进行正交试验分析,找出了影响较大的因素。采用在减小回弹的基础上控制型材厚度变化率的综合质量损失为目标函数,用响应面模型对其进行函数拟合,然后利用遗传算法对目标函数进行稳健优化。试验验证结果表明:采用该方法进行稳健优化设计后,能够在满足约束条件的情况下有效减小综合质量损失。
The uncontrollable factors and controllable factors of the profile of three-dimensional flexible stretch bending forming are analyzed.Based on the analysis,a comprehensive quality evaluation method of three-dimensional stretch bending and a robust optimization method are proposed.The uncontrollable factors and controllable factors are analyzed based on orthogonal experiments by finite element simulations,and the factors greatly influencing the forming quality are identified.The comprehensive quality evaluation method is established using the loss of comprehensive quality as the optimization objective.The objective includes reducing the springback and controlling the change rate of profile thickness.The response surface model is adopted to carry out the fitting function.Genetic algorithm is applied for robust optimization,and the optimization results are validated.The results show that the robust optimization method can effectively reduce the comprehensive quality loss while the constraints are satisfied.
The uncontrollable factors and controllable factors of the profile of three-dimensional flexible stretch bending forming are analyzed.Based on the analysis,a comprehensive quality evaluation method of three-dimensional stretch bending and a robust optimization method are proposed.The uncontrollable factors and controllable factors are analyzed based on orthogonal experiments by finite element simulations,and the factors greatly influencing the forming quality are identified.The comprehensive quality evaluation method is established using the loss of comprehensive quality as the optimization objective.The objective includes reducing the springback and controlling the change rate of profile thickness.The response surface model is adopted to carry out the fitting function.Genetic algorithm is applied for robust optimization,and the optimization results are validated.The results show that the robust optimization method can effectively reduce the comprehensive quality loss while the constraints are satisfied.
引文
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[2]梁继才,滕菲,高嵩,等.柔性三维拉弯成形模具型面修正关键技术的研究[J].机械工程学报,2013,49(17):187-192.Liang Ji-cai,Teng Fei,Gao Song,et al.Key technologies research on the iterative die-face adjustment in the forming process of flexible three-dimensional stretch-bending[J].Journal of Mechanical Engineering,2013,49(17):187-192.
[3]梁继才,滕菲,高嵩,等.矩形铝型材柔性三维拉弯工艺的多目标优化[J].华南理工大学学报:自然科学版,2013,41(9):143-148.Liang Ji-cai,Teng Fei,Gao Song,et al.Multi-objective optimization of flexible three-dimensional stretch-bending forming process of rectangular hollow aluminum profiles[J].Journal of South China University of Technology(Natural Science Edition),2013,41(9):143-148.
[4]Tryand T,Hopperstad O S,Langseth M.Design of experiments to identify material properties[J].Materials and Design,2000,21:477-492.
[5]Miller J E,Kyriakids S,Bastard A H.On bendstretch forming of aluminum extruded tubes-Ⅰ:experiments[J]International Journal of Mechanical Sciences,2001,43:1283-1317.
[6]Miller J E,Kyriakids S,Bastard A H.On bendstretch forming of aluminum extruded tubes-П:analysis[J]International Journal of Mechanical Sciences,2001,43:1319-1338.
[7]Hopperstad O S,Remseth S,Lerira B,et al.Reliability-based analysis of a stretch-bending process for aluminum extrusions[J].Computers and Structures,1999,71:63-75.
[8]栾军.现代试验设计与优化方法[M].上海:上海交通大学出版社,1995:42-56.
[9]陈立周.稳健设计[M].北京:机械工业出版社,2000:23-45.
[10]Tang Y C,Chen J.Robust design of sheet metal forming process based on adaptive importance sampling[J].Structural and Multidisciplinary Optimization,2009,39(5):531-544.
[11]谢延敏.基于动态Kriging模型的板料成形工艺稳健设计[J].西南交通大学学报,2014,49(1):160-164.Xie Yan-min.Robust design of sheet forming process based on dynamic kriging model[J].Journal of Southwest Jiaotong University,2014,49(1):160-164.
[12]郭宝峰,杨艳子,金淼.塑形成形工艺参数稳健优化设计方法[J].塑形工程学报,2009,16(6):1-5.Guo Bao-feng,Yang Yan-zi,Jin Miao.The study on the robust optimization designing method for the technical parameters of plastic forming processes[J].Journal of Plasticity Engineering,2009,16(6):1-5.
[13]胡静,谢延敏,王智,等.基于Dual-Kriging模型多目标稳健设计在板料拉伸成形中的应用[J].塑性工程学报,2013,20(3):37-42.Hu Jing,Xie Yan-min,Wang Zhi,et al.The application of multi-objective robust design based on Dual-Kriging in the sheet drawing process[J].Journal of Plasticity Engineering,2013,20(3):37-42.
[14]Box G E P,Wilson K B.On the experimental attainment of optimum conditions[J].Journal of the Royal Statistical Society Series B,1951,13(1):1-45.
[15]Chen L H.Designing robust products with multiple quality characteristics[J].Computers Operations Research,1997,24(10):937-944.